Mixed material apron sink

ABSTRACT

A sink includes a basin body having a generally concave shape that forms at least one sink basin, a top flange integrally formed with the basin body, the top flange extending around the at least one sink basin, an apron connected to a front edge of the top flange, a replaceable panel removably connected to the apron, and a fastening system disposed between the apron and the replaceable panel, the fastening system releasably connecting the replaceable panel to the apron.

FIELD OF THE DISCLOSURE

The present disclosure relates to sinks and, more particularly, sinks with aprons.

BACKGROUND OF THE INVENTION

Sinks with aprons, which are also sometimes referred to as farmhouse sinks, are a popular type of sink used in residential and commercial applications. Such sinks can be constructed from various materials including fireclay, copper, steel, and the like, and also from composite materials such as engineered stone, which is a composite material made from crushed stone that is bound together by an adhesive such as a polymer resin.

Sinks of this style are typically formed or fabricated to a desired shape in which a sink basin includes an apron, which is visible from the front of the cabinet or stand into which the sink is installed. While various materials can be used to provide a desired aesthetic effect, when the surrounding cabinets or décor is updated, the sink and other fixtures often require replacement. Sinks in general, and especially apron sinks, are heavy and typically require modification of the base cabinet when a different sink is installed because of the modifications that are required to install the original sink and remove a front portion of the cabinet to accommodate the apron. Replacement of a base cabinet along with the sink will typically increase the cost and complexity of a remodeling project.

SUMMARY OF THE DISCLOSURE

In one aspect, the disclosure describes a sink. The sink includes a basin body having a generally concave shape that forms at least one sink basin, a top flange integrally formed with the basin body, the top flange extending around the at least one sink basin, an apron connected to a front edge of the top flange, a replaceable panel removably connected onto the apron, and a fastening system disposed between the replaceable panel and the apron, the fastening system releasably connecting the replaceable panel to the apron.

In another aspect, the disclosure describes a method of using a sink having a replaceable panel connected to an apron. The method includes providing a basin body having a top flange integrally formed with the basin body, the top flange extending around the at least one sink basin. The method further includes providing an apron extending from a front edge of the top flange, and removably connecting a replaceable panel to the apron using a fastening system disposed between the replaceable panel and the apron.

In yet another aspect, the disclosure describes a method of assembling a sink having a replaceable panel connected to an apron. The method includes providing a sink having an apron, installing the sink into a cabinet section, and releasably securing a replaceable panel to the apron of the sink. In one embodiment, the method further includes removing the replaceable panel from the apron while the sink is installed into the cabinet section, and releasably securing a second replaceable panel to the apron of the sink while the sink is installed into the cabinet section.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is an outline view of an apron sink installed in a cabinet section in accordance with the disclosure.

FIG. 2 is an outline view of an apron sink installed on a based cabinet in accordance with the disclosure.

FIG. 3 is a cross sectional view of the sink of FIG. 1 as installed on a base cabinet.

FIG. 4 is an outline view of a mixed material apron sink in accordance with the disclosure.

FIGS. 5 and 6 are disassembled views from different perspectives of a sink in accordance with the disclosure.

FIGS. 7 and 8 are enlarged, detailed views of the sink of FIG. 1 in its installed position.

DETAILED DESCRIPTION

The present disclosure is applicable for fixtures such as sinks that have aprons and, more particularly, to an apron sink having a removable or replaceable panel that is releasably connected to a front of the apron. A sink 100 installed in a cabinet section 102 is shown in FIG. 1. The installation of the sink 100 in the cabinet section 102 is shown as an exemplary installation for the sink 100, but other installation methods or types can also be used. In the embodiment shown, the sink 100 is installed on a base cabinet 104 and is surrounded by two side cabinets 106. Each of the two side cabinets 106 includes a countertop section 108 having an end 110 that faces the sink 100 and overlaps a top flange 112 of the sink 100. The top flange 112 of the sink 100 extends across an entire width, W (FIG. 1), and can include an opening to support a faucet 114 along a portion of the top flange 112 that defines a faucet deck as shown. The sink 100 further includes a basin 116 and a replaceable panel 118 that is exposed on the front side of the cabinet section 102 and forms a portion of a cabinet face 119.

An outline view of the sink 100 installed into the base cabinet 104 with the surrounding structures removed for illustration is shown in FIG. 2. A cross section view of the sink 100 installed in the base cabinet 104 is shown in FIG. 3. As can be seen from these illustrations, the base cabinet 104 includes two sidewalls 202, a back wall 203, and a floor 204 to form a generally rectangular box structure that is open at the top and front. The top flange 112 of the sink 100 rests along a top edge 206 of the side and back walls 202 and 203 to support the weight of the sink 100. Beams 208 connect the two sidewalls 202 along the top, front of the base cabinet 104 and, optionally, along the top of a cabinet door opening 210. As shown in FIG. 3, the top flange 112 includes an apron 212 that extends perpendicularly relative to the top flange 112 in a downward direction around the topmost beam 208. The apron 212 has a generally rectangular shape as is connected along its top edge to a front edge of the top flange 112. Along a bottom edge, the apron 212 includes a shelf 214 that extends perpendicularly relative to the apron 212 along a plane that is parallel to a plane defined by the top flange 112 in an outward direction. In the illustrated embodiment, the replaceable panel 118 is disposed in contact with and connected to the apron 212 and the shelf 214.

An outline view of the sink 100 is shown in FIG. 4, and partially disassembled views of the sink 100 are shown in FIGS. 5 and 6 from different perspectives. In the description that follows, structures and features of the sink 100 and/or the cabinet section 102 are denoted with the same reference numerals as previously used for simplicity. In reference to FIGS. 4, 5 and 6, the sink 100 is generally formed as a rectangular basin sink that includes a basin 120. Although a single, basin 120 is shown, more than one basin may be included in the sink 100 and separated from one or more adjacent basins by a divider wall (not shown). The basin 120 is surrounded by a front wall 122 (shown in FIG. 3), a back wall 124, two sidewalls 126 and a floor 128 that includes a drain opening 130.

As can be seen from FIG. 5, the sink 100 may be fabricated from steel sheet, for example, stainless steel, as a unitary structure that includes welded and/or drawn portions. In the illustrated embodiment, the basin 120 along with the front wall 122, the back wall 124, the two sidewalls 126 and the floor 128 can be formed by a single, drawn sheet of steel into a box-shape having an open top. The top flange 112, along with the apron 212 and the shelf 214 can be formed by a single sheet of steel that has a basin opening punched into it along an opening 132 and is also bent to a desired shape to form the top flange 112, the apron 212 and the shelf 214. The walls surrounding the basin 120 can then be welded to the top flange 112 along the 132 that surrounds the basin to form the sink 100. The welded seam can be rounded and ground to a desired finish so the sink 100 appears continuous along the seam between the basin and the top flange.

The sink 100 advantageously includes a fastening system 300 to removably attach the replaceable panel 118 onto the apron 212 and/or shelf 214 so that the replaceable panel 118 can be replaced without removing the sink 100 or adjusting any of the plumbing or drain connections. In the illustrated embodiment, the fastening system 300 includes cooperating fasteners with openings in the sink. More specifically, as shown in FIG. 6 with the replaceable panel 118 removed, the apron 212 includes two key openings 304, each of which includes a central opening 306 and two slots 308 extending horizontally on either side of the central opening 306. The central opening 306 is sized to accept therethrough the head of a fastener 310, shown in the cross section of FIG. 7. For securing the replaceable panel 118 to the apron 212, the fastener 310 is installed into the back side of the replaceable panel 118 such that a threaded portion 312 of the fastener 310 threadably engages a threaded opening 314 formed in the backside of the replaceable panel 118. A spring washer 316 such as a Belleville washer is inserted along the body of the fastener 310 and disposed between a head 318 and a rear surface of the apron 212. A feature 320 such as a slot is formed in the head 318 of the fastener to allow its tightening and loosening.

When installing the replaceable panel 118, the fastener 310 and spring washer 316 are loosely secured to the back side of the replaceable panel 118 before inserting the head 318 of the fastener 310 and also the spring washer 316 through the central opening 306 of the apron 212. This can be done twice, once on either side of the apron 212. The replaceable panel 118 along with the two fasteners 310 inserted through their corresponding central openings 306 are then slid along the sink 100 such that the bodies of the respective fasteners travel along the corresponding slot 308. The thickness of the apron 212, which is now disposed between the head 318 and the rear face of the apron 212 causes the spring washer 316 to compress and maintain a clamping force between the replaceable panel 118 and the apron 212 of the sink 100. To secure the replaceable panel 118 and prevent sliding when the replaceable panel 118 is at its final position relative to the sink, two retaining screws 322 can be inserted into mating threaded openings 324 at the bottom face of the replaceable panel 118 through corresponding holes 326 formed in the shelf 214, as shown in FIG. 8.

As can be appreciated, the process to remove the replaceable panel 118 from the sink 100 for replacement can be the reverse of the installation procedure. For removing the replaceable panel 118, the two screws 322 can be removed and the replaceable panel 118 slid along the slots 308 in the apron 212 such that the fasteners 310 move towards their respective central openings 306. When the spring washers 316 and corresponding heads 318 of the fasteners 310 are aligned in the central openings 306, the replaceable panel 118 can be removed and replaced with a different replaceable panel 118.

The fastening system 300, while described relative to fasteners and spring washers can be embodied in different configurations. For example, the fasteners can be replaced by hooks that engage slots formed in the apron, or with slots formed in the replaceable panel that engage rails protruding from the front surface of the apron 212. Moreover, while the sink 100 is made from stainless steel, in can be constructed with other metals or materials including composite materials such as engineered stone. The replaceable panel can be made from any desired material such as ceramic, plastic, composite, metal, or wood, which can be solid or veneered wood, and the like. Further, while the replaceable panel 118 is shown having a smooth finish, it can include any type of finish and/or include a relief design. The replaceable panel may also be made from two or more connected structures and may include components such as lights, electronic displays and the like.

All references, including publications, patent applications, and patents, cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.

The use of the terms “a” and “an” and “the” and “at least one” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The use of the term “at least one” followed by a list of one or more items (for example, “at least one of A and B”) is to be construed to mean one item selected from the listed items (A or B) or any combination of two or more of the listed items (A and B), unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.

Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context. 

1. A sink, comprising: a basin body having a generally concave shape that forms at least one sink basin; a top flange integrally formed with the basin body, the top flange extending around the at least one sink basin; an apron connected to a front edge of the top flange; a replaceable panel removably connected to the apron; and a fastening system disposed between the replaceable panel and the apron, the fastening system releasably connecting the replaceable panel to the apron.
 2. The sink of claim 1, wherein the basin body includes a basin that is at least partially defined between a front wall, a back wall, two sidewalls and a floor that includes a drain opening.
 3. The sink of claim 2, wherein the basin body is fabricated from steel sheet.
 4. The sink of claim 2, wherein the apron extends perpendicularly relative to the top flange in a downward direction and at an offset distance relative to the front wall of the basin body.
 5. The sink of claim 4, wherein the apron has a generally rectangular shape and is connected along its top edge to a front edge of the top flange.
 6. The sink of claim 5, further comprising a shelf connected to the apron, the shelf extending perpendicularly relative to the apron along a plane that is parallel to a plane defined by the top flange, in an outward direction.
 7. The sink of claim 6, wherein the replaceable panel is fastened to the apron and the shelf.
 8. The sink of claim 1, wherein the apron includes two central openings, each central opening having two slots extending therefrom in a horizontal direction.
 9. The sink of claim 8, wherein the fastening system includes two fasteners and two spring washers, each of the two fasteners threadably engaging a corresponding threaded opening in the replaceable panel and including one of the two spring washers disposed between a head of the fastener and a rear face of the apron when the fastener extends through the apron via a corresponding one of the two slots.
 10. A method of using a sink having an apron, comprising: providing a basin body having a top flange integrally formed with the basin body, the top flange extending around the at least one sink basin; providing an apron extending from a front edge of the top flange; removably connecting a replaceable panel to the apron using a fastening system disposed between the replaceable panel and the apron.
 11. The method of claim 10, wherein the basin body is fabricated from steel sheet.
 12. The method of claim 11, wherein the apron extends perpendicularly relative to the top flange in a downward direction and at an offset distance relative to the front wall of the basin body.
 13. The method of claim 12, further comprising providing a shelf connected to the apron, the shelf extending perpendicularly relative to the apron along a plane that is parallel to a plane defined by the top flange, in an outward direction.
 14. The method of claim 13, wherein removably connecting the replaceable panel includes fastening the replaceable panel to the apron and the shelf.
 15. The method of claim 10, wherein the fastening system includes two fasteners and two spring washers, each fastener engaged with the replaceable panel, and each spring washer engaged in compression between a head of a corresponding fastener and a rear surface of the apron.
 16. The method of claim 15, wherein the apron includes two key openings, each key opening having a central opening and a slot extending from the central opening.
 17. The method of claim 16, wherein removably connecting the replaceable panel to the apron includes: loosely securing one of the two fasteners having a spring washer thereon into a threaded opening in the replaceable panel; passing the spring washer and the head of the fastener through a central opening of one of the two key openings; sliding the replaceable panel relative to the sink such that a body of the fastener enters the channel; and compressing the spring washer between the head of the fastener and the rear surface of the apron.
 18. The method of claim 17, further comprising inserting a screw through an opening in the shelf and engaging the screw with a bottom face of the replaceable panel to secure the replaceable panel against sliding relative to the sink.
 19. A method of assembling a sink having a replaceable panel, comprising: providing a sink having an apron; installing the sink into a cabinet section; and releasably securing the replaceable panel to the apron of the sink.
 20. The method of claim 19, further comprising: removing the replaceable panel from the sink while the sink is installed into the cabinet section; and releasably securing a second replaceable panel to the apron of the sink while the sink is installed into the cabinet section. 